Positive electrode active material for lithium ion secondary battery and lithium ion secondary battery

ABSTRACT

A positive electrode active material is constituted by lithium transition metal-containing composite oxide particles having a layered rock salt type crystal structure and are composed of secondary particles each formed of an aggregation of primary particles. The secondary particles have a d50 of 3.0 to 7.0 μm, a BET specific surface area of 1.8 to 5.5 m 2 /g, a pore peak diameter of 0.01 to 0.30 μm, and a log differential pore volume [dV/d(log D)] of 0.2 to 0.6 ml/g within a range of the pore peak diameter. In each of a plurality of primary particles having a primary particle size of 0.1 to 1.0 μm, a coefficient of variation of the concentration of an additive element M is 1.5 or less.

TECHNICAL FIELD

The present invention relates to a positive electrode active material for a lithium ion secondary battery formed of a lithium transition metal-containing composite oxide and a lithium ion secondary battery using the positive electrode active material for a lithium ion secondary battery as a positive electrode material.

BACKGROUND ART

In recent years, with spread of a portable electronic device such as a smartphone, a tablet terminal, a digital camera, or a notebook personal computer, there is a strong demand for development of a small and lightweight secondary battery having a high energy density. Furthermore, there is a strong demand for development of a high-capacity and high-output secondary battery as a power source for an electric car such as a hybrid electric car, a plug-in hybrid electric car, or a battery-powered electric car.

As a secondary battery satisfying such a requirement, there is a lithium ion secondary battery. This lithium ion secondary battery includes a negative electrode, a positive electrode, a non-aqueous electrolyte or a solid electrolyte, and the like, and as an active material used as a material for these negative electrode and positive electrode, a material capable of de-inserting and inserting lithium is used. Note that, as the non-aqueous electrolyte, there is a non-aqueous electrolyte solution that is obtained by dissolving a lithium salt as a supporting salt in an organic solvent, and as the solid electrolyte, there is an inorganic or organic solid electrolyte that is non-flammable and has lithium ion conductivity.

Among lithium ion secondary batteries, a lithium ion secondary battery using a lithium transition metal-containing composite oxide having a layered rock salt type or spinel type crystal structure as a positive electrode material has been researched and developed and has been put into practical use as a battery having a high energy density because a voltage at a level of 4 V can be obtained.

As the positive electrode material of the lithium ion secondary battery, positive electrode active materials formed of lithium transition metal-containing composite oxides such as lithium cobalt composite oxide (LiCoO₂) for which synthesis is relatively easy, lithium nickel composite oxide (LiNiO₂) that uses nickel less expensive than cobalt, lithium nickel manganese cobalt composite oxide (LiNi_(1/3)Mn_(1/3)Co_(1/3)O₂), lithium manganese composite oxide (LiMn₂O₄) that uses manganese, and lithium nickel manganese composite oxide (LiNi_(0.5)Mn_(0.5)O₂) have been proposed.

In recent years, a ternary-system positive electrode active material formed of lithium nickel manganese cobalt-containing composite oxide (NMC) containing at least nickel, manganese, and cobalt as a transition metal, including lithium nickel manganese cobalt composite oxide (LiNi_(1/3)Mn_(1/3)Co_(1/3)O₂) of these lithium transition metal-containing composite oxides, has attracted attention as a material that is excellent in thermal stability, has a high capacity, has also satisfactory cycle characteristics of a battery capacity, has a low resistance and is capable of obtaining a high output. The lithium nickel manganese cobalt composite oxide is a compound having a layered rock salt type crystal structure that is similar to lithium cobalt composite oxide, lithium nickel composite oxide, and the like.

The lithium transition metal-containing composite oxide has been developed focusing on an increase in output by reducing its internal resistance. In particular, in power application for an electric car, higher output by further reducing internal resistance is required at a high level.

In order to improve the output characteristics and cycle characteristics of the positive electrode active material formed of a lithium transition metal-containing composite oxide such as lithium nickel-containing composite oxide or lithium nickel manganese cobalt-containing composite oxide, it is important to constitute the lithium transition metal-containing composite oxide with particles having a small particle size and a narrow particle size distribution. Particles having a small particle size have a large specific surface area, and when such particles are used as a positive electrode active material, a reaction area with an electrolyte can be sufficiently secured. Furthermore, the particles form a thin positive electrode, and a movement distance of lithium ions between a positive electrode and a negative electrode can be shortened. Therefore, by using particles having a small particle size, positive electrode resistance can be reduced. Furthermore, by using particles having a narrow particle size distribution, a voltage to be applied to particles in an electrode can be made uniform, and therefore a decrease in battery capacity due to selective degradation of fine particles can be suppressed.

In order to further improve the output characteristics, it has been researched and developed that the particle structure of the lithium transition metal-containing composite oxide is improved. For example, in order to improve the output characteristics, it is conceivable that forming of a space section which an electrolyte can enter inside the positive electrode active material is effective. By adopting such a structure, as compared with a positive electrode active material with a solid structure having the sane degree of particle size, the reaction area with the electrolyte can be increased. Therefore, the positive electrode resistance can be considerably reduced. Note that it is known that the positive electrode active material inherits the particle properties of a transition metal-containing composite hydroxide serving as a precursor thereof. That is, in order to obtain the positive electrode active material having a space section, it is necessary to appropriately control the particle size, the particle size distribution, the particle structure, and the like of secondary particles of the transition metal-containing composite hydroxide serving as a precursor of the positive electrode active material.

For example, JP 2012-246199 A and WO 2012/131881 A1 disclose a method for manufacturing transition metal-containing composite hydroxide particles serving as a precursor of a positive electrode active material by a crystallization reaction clearly separated into two stages of a nuclear generation process of mainly performing nuclear generation and a particle growth process of mainly performing particle growth. In the method, by appropriately adjusting a pH value and a reaction atmosphere in the nuclear generation process and the particle growth process, transition metal-containing composite hydroxide particles having a small particle size, a narrow particle size distribution, and formed of a low-density center including fine primary particles and a high-density outer shell section including plate-shaped or needle-shaped primary particles are obtained, and a positive electrode active material obtained from such composite hydroxide particles has a hollow structure, has a large contact area with an electrolyte solution, and can improve output characteristics.

WO 2014/181891 A1 and JP 2018-104276 A disclose a method for manufacturing transition metal-containing composite hydroxide particles, the method including: a nuclear generation process of performing nuclear generation by controlling a pH value of an aqueous solution for nuclear generation containing at least a transition metal-containing metal compound and an ammonium ion supplier so as to be within a range of 12.0 or more and 14.0 or less; and a particle growth process of growing particles by controlling a pH value of an aqueous solution for particle growth containing the generated nuclei so as to be lower than the pH value in the nuclear generation process and within a range of 10.5 or more and 12.0 or less, in which atmosphere control of setting an atmosphere of the nuclear generation process and an initial stage of the particle growth process to a non-oxidizing atmosphere, switching the atmosphere to an oxidizing atmosphere at a predetermined timing in the particle growth process, and then switching the atmosphere to the non-oxidizing atmosphere again is performed at least once. According to this method, it is possible to obtain transition metal-containing composite hydroxide particles having a small particle size, a narrow particle size distribution, and having a center section formed of an aggregation of plate-shaped or needle-shaped primary particles, and two laminated structures formed outside the center section each of which a low density layer formed of an aggregation of fine primary particles and a high density layer formed of an aggregation of plate-shaped primary particles are alternately laminated.

A positive electrode active material using the transition metal-containing composite hydroxide particles as a precursor has a small particle size, a narrow particle size distribution, and a hollow structure or a multilayer structure having a space section. Therefore, in a secondary battery using the positive electrode active material, it is possible to simultaneously improve battery capacity, output characteristics, and cycle characteristics.

CITATION LIST Patent Literature

Patent Literature 1:JP 2012-246199 A

Patent Literature 2:WO 2012/131581A1

Patent Literature 3:WO 2014/181891A1

Patent Literature 4:JP 2018-104276A

SUMMARY OF INVENTION Technical Problem

However, since there is room for improvement in output characteristics of the positive electrode active materials described in these literatures, further improvement in output characteristics is required.

In view of the above problems, an object of the present invention is to provide a positive electrode active material for a lithium ion secondary battery capable of exhibiting excellent output characteristics when the positive electrode active material is used in a lithium ion secondary battery.

Solution to Problem

A positive electrode active material for a lithium ion secondary battery according to an aspect of the present invention includes:

composite oxide particles constituted by lithium transition metal-containing composite oxide particles having a composition represented by general formula (A): Li_(1+u)Ni_(x)Mn_(y)Co_(z)M_(t)O₂, where −0.05≤u≤0.5, x+y+z+t=1, 0.3≤x≤0.9, 0≤y≤0.5, 0≤z≤0.5, 0≤t≤0.1, and M is one or more additive elements selected from Mg, Al, Si, Ca, Ti, V, Cr, Zr, Mb, Mo, Hf, Ta, and V, and a layered rock salt type crystal structure, in which

the lithium transition metal-containing composite oxide particle are composed of secondary particles each formed of an aggregation of primary particles,

the secondary particles have:

a 50% cumulative diameter d50 of 3.0 μm or more and 7.0 μm or less, the 50% cumulative diameter d50 being determined from a particle size distribution measured value,

a BET specific surface area of 1.8 m²/g or more and 5.5 m²/g or less,

a pore peak diameter of 0.01 μm or more and 0.30 μm or less in a pore portion obtained by a mercury intrusion method, and

a log differential pore volume [dV/d(log D)] of 0.2 ml/g or more and 0.6 ml/g or less within a range of the pore peak diameter of 0.01 μm or more and 0.30 μm or Less, and

for each of a plurality of primary particles having a primary particle size within a range of 0.1 μm or more and 1.0 μm or less among the primary particles, when a concentration of the additive element M is measured at a plurality of locations by cross-sectional STEM or TEM-EDX analysis, and a coefficient of variation of the concentration of the additive element M, which is a value obtained by dividing a standard deviation of the concentration of the additive element M by an average concentration of the additive element M, is calculated, the coefficient of variation is 1.5 or less.

The 50% cumulative diameter d50 of the secondary particles is preferably 4.0 μm or more and 6.0 μm or less.

[(d90-d10)/d50], where d10 is a 10% cumulative diameter determined from a particle size distribution measured value, and d90 is a 90% cumulative diameter determined from the particle size distribution measured value, the [(d90−d10)/d50] being an index indicating spread of a particle size distribution of the secondary particles, is preferably 1.0 or less.

A value of d90/d10 of the secondary particles is preferably 1.0 or more and 2.0 or less.

The secondary particle preferably has an aggregated section, one or more communication holes communicating with an outer periphery section of the aggregated section, and two or more space sections present inside the aggregated section and communicating with the one or more communication holes. The number of the one or more communication holes is preferably two or more. The two or more space sections preferably communicate with the one or more communication holes or another space section.

The additive element M is preferably one or more selected from Mg, Al, Si, Ti, Zr, Nb, Mo, and W. The additive element M is preferably W.

A lithium ion secondary battery according to an aspect of the present invention is characterized by including a positive electrode, a negative electrode, a separator, and a non-aqueous electrolyte in a case of a non-aqueous electrolyte secondary battery, or including a positive electrode, a negative electrode, and a solid electrolyte in a case of a solid electrolyte secondary battery, in which the positive electrode active material for a lithium ion secondary battery of an aspect of the present invention is used as a positive electrode active material used in the positive electrode.

ADVANTAGEOUS EFFECTS OF INVENTION

In the positive electrode active material for a lithium ion secondary battery according to an aspect of the present invention, a contact area with a non-aqueous electrolyte or a solid electrolyte is sufficiently large, and therefore insertion and de-insertion of lithium ions at a particle interface are promoted, and output characteristics of the positive electrode active material can be improved. Therefore, a lithium ion secondary battery to which the positive electrode active material for a lithium ion secondary battery according to an aspect of the present invention is applied can provide high output characteristics, and therefore industrial significance thereof is very large.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is an SEM image of a cross section of secondary particles constituting a positive electrode active material for a lithium ion secondary battery of Example 1 of the present invention.

FIG. 2 is an SEM image of a cross section of secondary particles constituting a positive electrode active material for a lithium ion secondary battery of Comparative Example 1.

FIG. 3 is a schematic cross-sectional view of a 2032 type coin-type battery used for battery evaluation.

FIG. 4 is a graph illustrating a measurement example of impedance evaluation.

FIG. 5 is a schematic explanatory diagram of an equivalent circuit used for analysis.

DESCRIPTION OF EMBODIMENTS 1. Positive Electrode Active Material for Lithium Ion Secondary Battery

A positive electrode active material for a lithium ion secondary battery (hereinafter, referred to as a “positive electrode active material”) according to an example of an embodiment of the present invention includes lithium transition metal-containing composite oxide particles (hereinafter, referred to as “composite oxide particles”), and satisfies the following requirements (1) to (7).

(1) Composition

The composite oxide particles have a composition represented by general formula (A) : Li_(1+u)Ni_(x)Mn_(y)Co_(z)M_(t)O₂, where −0.05≤u≤0.5, x+y+z+t=1, 0.3≤x≤0.9, 0p≤y≤0.5, 0≤z≤0.5, 0<t≤0.1, and M is one or more additive elements selected from Mg, Al, Si, Ca, Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, and W.

In the positive electrode active material of the present invention, a value of u indicating an excessive amount of lithium (Li) is −0.05 or more and 0.5or less. The value of u is preferably 0 or more and 0.50or less, and more preferably 0 or more and 0.35 or less. By regulating the value of u to be within the above range, it is possible to improve output characteristics and battery capacity of a lithium ion secondary battery using this positive electrode active material as a positive electrode material. On the other hand, when the value of u is less than −0.05, positive electrode resistance of the secondary battery is large, and therefore there is a possibility that the output characteristics cannot be improved. When the value of u exceeds 0.5, not only initial discharge capacity decrease, but also there is a possibility that the positive electrode resistance increases.

Nickel (Ni) is an element that contributes to potential increase and capacity enlargement of a secondary battery, and a value of x indicating the content of nickel is 0.3 or more and 0.9 or less. The value of x is preferably 0.4 or more and 0.7 or less, and more preferably 0.4 or mere and 0.6 or less. When the value of x is less than 0.3, there is a possibility that the energy density of a secondary cattery using this positive electrode active material cannot be sufficiently improved. when the value of x exceeds 0.9, the content of another element that improves output characteristics and durability characteristics decreases, and there is a possibility that characteristics as a positive electrode active material cannot be sufficiently obtained.

Manganese (Mn) is an element that contributes to improvement of thermal stability, and a value of y indicating the content of manganese is 0 or more and 0.5 or less. The value of y is preferably 0.1 or more and 0.4 or less. When the value of y exceeds 0.5, Mn elutes from the positive electrode active material during high-temperature operation, and charge and discharge cycle characteristics may deteriorate.

Cobalt (Co) is an element that contributes to improvement of charge and discharge cycle characteristics and output characteristics, and a value of z indicating the content of cobalt is 0 or more and 0.5 or less. The value of y is preferably 0.1 or more and 0.4 or less. When the value of z exceeds 0.5, initial discharge capacity of a secondary battery using this positive electrode active material may decrease.

The positive electrode active material of the present invention can contain the following additive element M. As the additive element M, it is possible to use one or more selected from magnesium (Mg), aluminum (Al), silicon (Si), calcium (Ca), titanium (Ti), vanadium (V), chromium (Cr), zirconium (Zr), niobium (Nb), molybdenum (Mo), hafnium (Hf), tantalum (Ta), and tungsten W.

The additive element M is preferably at least one selected from the group consisting of Mg, Al, Si, Ti, Zr, Nb, Mo, and W, and is more preferably W.

A value of t indicating the content of the additive element M is more than 0 and 0.05 or less. The value of t is preferably 0.001 or more and 0.03 or less. When the value of t exceeds 0.05, a metal element that contributes to a Redox reaction decreases, and therefore battery capacity of the secondary battery decreases.

The additive element M may be dispersed inside the composite oxide particles or may be coated on a surface of the composite oxide particles. In any case, it is preferable to control the content of the additive element M to be within the above range.

The composite oxide particles of the present invention are preferably constituted by a lithium nickel manganese cobalt-containing composite oxide (NMC) containing Ni, Mn, and Co as main transition metals. In this case, the composite oxide particles preferably have a composition represented by general formula (B): Li_(1+u)Ni_(x)Mn_(y)Co₂M_(t)O₂, where −0.05≤u≤0.5, x+y+z+t=1, 0.3≤x≤0.7, 0.15≤y≤0.4, 0.15≤z≤0.4, 0<t≤0.05, and M is one or more additive elements selected from Mg, Al, Si, Ca, Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, and W.

The composition of the positive electrode active material can be confirmed by, for example, Rietveld analysis of parameters obtained by inductively coupled plasma emission spectrometry and powder X-ray diffraction.

When the positive electrode active material of the present invention has the composition of the general formula (A) or (B), the positive electrode active material has a layered rock salt type hexagonal crystal structure.

(2) Particle Structure

In the positive electrode active material of the present invention, the composite oxide particles are composed of secondary particles each formed of an aggregation of a plurality of primary particles.

The secondary particle preferably has an aggregated section, one or more communication holes communicating with an outer periphery section of the aggregated section, and two or more space sections present inside the aggregated section and communicating with the one or more communication holes.

The two or wore space sections preferably communicate with the one or more communication holes or another space section. The number of the one or more communication holes is also preferably two or more.

When the composite oxide particles have such a secondary particle structure, particle properties of the positive electrode active material of the present invention described later can be easily achieved.

When the communication hole in the outer periphery section does not communicate with the internal space section, the space section inside the particle is isolated, an electrolyte cannot sufficiently enter the composite oxide particle (secondary particle), and a sufficient reaction field cannot be secured. Therefore, in a secondary battery using this positive electrode active arterial, desired battery performance cannot be sufficiently exhibited in some cases. Each of the two or more internal space sections can directly communicate with the one or more communication holes in the outer periphery section. Alternatively, each of the two or more internal space sections can communicate with a communication hole in the outer periphery section through another space section.

With such a structure, an electrolyte sufficiently enters the space section inside the particle through the communication hole in the outer periphery section. Therefore, lithium can be de-inserted and inserted not only on a surface of the particle but also inside the particle, a sufficient reaction field is secured, and the infernal resistance of the battery can be largely reduced.

Therefore, when a lithium ion secondary battery is constituted using a positive electrode active material having such a structure as a positive electrode material, the output characteristics can be further improved.

(3) Particle Size

In the positive electrode active material of the present invention, the secondary particles have a 50% cumulative diameter d50 of 3.0 μm or more and 7.0 μm or less, the 50% cumulative diameter d50 being determined fro(r) a particle size distribution measured value. The 50% cumulative diameter d50 of the secondary particles is preferably 4.0 μm or more and 6.5 μm or less, and more preferably 4.0 μm or more and 6.0 μm or less.

More specifically, the 50% cumulative diameter d50 is a particle size at which a cumulative volume determined from a volume integrated value measured with a laser light diffraction scattering particle size analyzer is 50% of the total volume of all particles (when a cumulative curve of the particle size distribution is determined by setting the total volume to 100%, the 50% cumulative diameter d50 is a particle size at a point where the cumulative curve is 50%).

When d50 of the particles constituting the positive electrode active material is within the above range, not only battery capacity per unit volume of a secondary battery using this positive electrode active material can be increased, but also safety and output characteristics can be improved.

On the other hand, when the 50% cumulative diameter d50 is less than 3.0 μm, a filling property of the positive electrode active material decreases, and there is a possibility that battery capacity per unit volume cannot be increased. When the 50% cumulative diameter d50 exceeds 7.0 μm, a reaction area of the positive electrode active material decreases, and an interface with an electrolyte is decreased. Therefore, there is a possibility that it is difficult to improve output characteristics.

(4) BET Specific Surface Area

In the positive electrode active material of the present invention, the secondary particles have a BET specific surface area of 1.8 m²/g or more and 5.5 m²/g or less. The BET specific surface area is preferably 2.0 m²/g or more and 5.0 m²/g or less, and more preferably 2.5 m²/g or more and 4.5 m²/g or less.

The BET specific surface area of the secondary particles is an index indicating particle properties (contact area with an electrolyte) of the positive electrode active material, when the secondary particle has an aggregated section, one or more communication holes communicating with an outer periphery section of the aggregated section, and two or more space sections present inside the aggregated section and communicating with the one or more communication holes, the BET specific surface area of the secondary particles represents a surface area including the one or more communication holes (opening sections) present in the outer periphery section of the secondary particle and fine cavities (space sections) inside the secondary particle.

The BET specific surface area is measured by a BET method using nitrogen gas adsorption.

When the BET specific surface area of the secondary particles is less than 1.8 m²/g, in a case where a secondary battery is constituted using this positive electrode active material, a reaction area with an electrolyte cannot be sufficiently secured, and there is a possibility that output characteristics cannot be sufficiently improved. When the BET specific surface area of the secondary particles exceeds 5.5 m2/g, the reaction area between the positive electrode active material and the electrolyte is too large, and durability of the secondary battery may be deteriorated.

(5) Pore Peak Diameter

In the positive electrode active material of the present invention, the secondary particles have a pore peak diameter of 0.01 μm or more and 0.30 μm or less in a pore portion obtained by a mercury intrusion method. The pore peak diameter is preferably 0.02 μm or more and 0.26 μm or less, and more preferably 0.05 μm or more and 0.25 μm or less.

Specifically, the pore peak diameter is defined as a diameter at which a pore peak is present in a pore distribution plot of the secondary particles obtained by a mercury intrusion method.

The pore peak diameter of the secondary particles is an index indicating the particle properties (average pore diameter) of the positive electrode active material. More specifically, when the pore peak diameter of the secondary particles constituting the positive electrode active material is within the above-described range, it means that the particles are a positive electrode active material having pores.

When the pore peak diameter of the secondary particles is less than 0.01 μm, since the pore diameter is small, the particle strength cannot be maintained and the particles are crushed, which nay impair battery performance. When the pore peak diameter of the secondary particles exceeds 0.30 μm, in a case where a secondary battery is constituted using this positive electrode active material, a reaction area with an electrolyte cannot be sufficiently secured, and there is a possibility that output characteristics cannot be sufficiently exhibited.

(6) Log Differential Pore Volume

In the positive electrode active material of the present invention, the secondary particles have a log differential pore volume [dV/d(log D)] of 0.2 ml/g or more and 0.6 ml/g or less within a range of the pore peak diameter of 0.01 μm or more and 0.30 μm or less. The log differential pore volume is preferably 0.2 ml/g or more and 0.6 ml/g or less, and more preferably 0.25 ml/g or more and 0.5 ml/g or less.

The log differential pore volume [dV/d(log D)] at the pore peak diameter is an index indicating the particle properties (volume of all cavities) of the positive electrode active material. More specifically, the log differential pore volume [dV/d(log D)] at the pore peak diameter is a value of the pore peak diameter in a log differential pore volume distribution determined by dividing a differential pore volume dV determined for each pore diameter by a difference value d(log D) in terms of logarithm of the pore diameter, based on a pore distribution plot of the secondary particles obtained by a mercury intrusion method. In the secondary particles constituting the positive electrode active material, when the log differential pore volume [dV/d(log D)] is within the above range, it means that an appropriate amount of space section is formed inside the particles, and a sufficient reaction area can be obtained.

When the log differential pore volume [dV/d(log D)] at the pore peak diameter is less than 0.2 ml/g, a sufficient space section is not formed inside the secondary particles, and a sufficient reaction area cannot be obtained in some cases, when the log differential pore volume [dV/d(log D)] at the pore peak diameter exceeds 0.6 ml/g, a large number of space sections are structurally present inside the secondary particles, and a bulk density is lowered to reduce a filling property. Therefore, when a secondary battery is constituted using the positive electrode active material, a battery capacity per unit volume cannot be sufficiently obtained in some cases.

(7) Coefficient of Variation of Concentration of Additive Element M

In the positive electrode active material of the present invention, a coefficient of variation (CV) indicating a variation in the concentration of the additive element M in the primary particles constituting the secondary particles is 1.5 or less. The coefficient of variation (CV) is preferably 1.3 or less, and more preferably 1.2 or less.

The coefficient, of variation of the concentration of the additive element M is an index indicating a variation of the concentration of the additive element M in the entire primary particles including the inside of the primary particles and grain boundaries.

The coefficient of variation of the concentration of the additive element M is determined as follows. First, the positive electrode active material is sectioned with a focused ion beam apparatus (FIB), an ion milling apparatus, or the like to expose a cross section of the secondary particles. Using a scanning transmission electron microscope (STEM) or a transmission electron microscope (TEM), two linked primary particles each having a primary particle size within a range of 0.1 μm or more and 1.0 μm or less in the cross section of the secondary particles are targeted, electron beam irradiation is performed on a plurality of locations for each of the two primary particles, and energy dispersive X-ray analyzer (EDX) analysis is performed on generated energy of a characteristic X-ray of the additive element M to determine the concentration of the additive element M at each location.

From the obtained data of the concentration of the additive element M, an average concentration (p) of the additive element M and a standard deviation (a) of the concentration of the additive element m are determined.

The coefficient of variation (CV) of the concentration of the additive element M is determined by a formula: CV=σ/μ.

When the coefficient of variation (CV) of the concentration of the additive element M exceeds 1.5, a distribution of the additive element M in the primary particles and/or the secondary particles is biased, and in a secondary battery using this positive electrode active material, battery performance such as battery capacity or output characteristics may be impaired.

(8) Particle Size Distribution

Optionally, in the positive electrode active material of the present invention, [(d90−d10)/d50], which is an index indicating spread of a particle size distribution of the secondary particles, is preferably 1.0 or less, more preferably 0.7 or less, and still more preferably 0.6 or less. In a positive electrode active material including secondary particles having such a narrow particle size distribution, a ratio of fine particles and coarse particles is small, and therefore a secondary battery using this positive electrode active material is excellent in all of safety, cycle characteristics, and output characteristics.

When [(d90−d10)/d50] exceeds 1.0, the ratio of fine particles and coarse particles in the positive electrode active material increases. For example, when the ratio of fine particles is large, the secondary battery is likely to generate heat due to localized reaction of the fine particles, and in addition to deterioration in safety, the fine particles may be selectively deteriorated to deteriorate cycle characteristics. Furthermore, when the ratio of coarse particles is large, a reaction area between an electrolyte and the positive electrode active material cannot be sufficiently secured, and output characteristics may be poor.

In a case of assuming industrial scale manufacturing, it is not realistic to use a positive electrode active material having an excessively small [(d90−d10)/d50]. Therefore, in consideration of cost and productivity, a lower limit of [(d90−d10)/d50] is preferably about 0.3.

Note that meanings and a method for determining d10 and d90 in the index [(d90−d10)/d50] indicating spread of a particle size distribution are similar to those in the case of d50 described above. d90 means a particle size at which an accumulated volume obtained by accumulating the volume of each particle from a side having a smaller particle size is 90% of the total volume of all particles, and d10 means a particle size at which an accumulated volume obtained by accumulating the volume of each particle from a side having a smaller particle size is 10% of the total volume of all particles.

(9) d90/d10

Optionally, in the positive electrode active material of the present invention, a ratio (d90/d10) of a value of d90 to a value of d10 determined from the particle size distribution measured value for the secondary particles is preferably 1.0 or more and 2.0 or less, and more preferably 1.2 or more and 1.8 or less.

When the value of d90/d10 of the secondary particles constituting the positive electrode active material is within the above range, not only battery capacity per unit volume of a secondary battery using this positive electrode active material can be increased, but also safety and output characteristics can be improved. When the value of d90/d10 of the secondary particles exceeds 2.0, a reaction area of the positive electrode active material decreases, and an interface with an electrolyte is decreased. Therefore, there is a possibility that it is difficult to improve output characteristics.

(10) Crystallite Diameter Determined From X-ray Diffraction Diagram of (003) Plane

Optionally, as for the composite oxide particles constituting the positive electrode active material of the present invention, when the crystallite diameter of the primary particle is determined from a full width at half maximum of a peak of a (003) plane by X-ray diffraction using a Scherrer formula, the crystallite diameter is preferably within a range of 300 Å to 1500 Å, more preferably within a range of 400 Å to 1300 Å, and still mere preferably within a range of 700 Å to 1250 Å. A positive electrode active material having a crystallite diameter within such a range has extremely high crystallinity, can reduce positive electrode resistance of a secondary battery, and can improve output characteristics thereof.

When the crystallite diameter of the (003) plane is less than 300 Å, the primary particles are fine, pores present between the primary particles in the positive electrode active material are too fine, and an electrolyte hardly enters the positive electrode active material. Therefore, a reaction area with the electrolyte is reduced, and output characteristics of the secondary battery are deteriorated. When the crystallite diameter of the (003) plane exceeds 1500 Å, the primary particles are too coarse, the ratio of pores in the secondary particles extremely decreases, and an entry path of an electrolyte decreases. Therefore, a reaction area with the electrolyte is reduced, and output characteristics of the secondary battery are deteriorated.

2. Method for Manufacturing Positive Electrode Active Material for Lithium Ion Secondary Battery

The positive electrode active material of the present invention is not limited by a method for manufacturing the positive electrode active material as long as the positive electrode active material has the above-described composition, crystal structure, particle structure, and particle properties.

However, by manufacturing the positive electrode active material of the present invention by a manufacturing method described below, a positive electrode active material having the above-described composition, crystal structure, particle structure, and particle properties can be easily manufactured.

Specifically, the positive electrode active material of the present invention is obtained by preparing a transition metal-containing composite hydroxide such as a nickel manganese cobalt-containing composite hydroxide by switching between an oxidizing atmosphere and a non-oxidizing atmosphere during a crystallization process, mixing the composite hydroxide or heat-treated particles obtained by heat-treating the composite hydroxide with a lithium compound, and firing the obtained lithium mixture.

Hereinafter, each process will be described in detail by exemplifying a case where the composite oxide particles are lithium nickel manganese cobalt-containing composite oxide particles.

(1) Crystallization Process

Water, a sodium hydroxide aqueous solution, and ammonia water are supplied into a reaction tank in appropriate amounts, and a pre-reaction aqueous solution is prepared such that a pH value based on the liquid temperature of 25° C. is 11 or more and 13 or less, and an ammonium ion concentration is 9 g/L or more and 15 g/L is prepared. It is desirable to prepare a raw material aqueous solution of 1.0 mol/L or more and 3.0 mol/L or less by dissolving nickel sulfate, manganese sulfate, cobalt sulfate, and a compound of the additive element H (a sulfate or a sodium salt) in water such that a molar ratio of each of the metal elements (Ni, Co, Mn, and M) satisfies the above formula (A). In order to suppress the coefficient of variation of the additive element M to be sol id-solved in the particles and to eliminate local coprecipitation of the additive element M around a transition metal element, it is more preferable to dissolve nickel sulfate, manganese sulfate, and cobalt sulfate in water such that a molar ratio of each of the metal elements (Ni, Co, and Mn) satisfies the above formula (A), to prepare a raw material aqueous solution of 1.0 mol/L or sore and 3.0 mol/L or less, to separately prepare an aqueous solution containing a compound of the additive element M, and to add the aqueous solution containing the compound of the additive element M to the raw material aqueous solution such that the addition amount of the additive element M satisfies the above formula (A).

Next, by supplying the raw material aqueous solution to the pre-reaction aqueous solution while blowing a gas in a non-oxidizing atmosphere having an oxygen concentration of 2% by volume or less, such as argon gas or nitrogen, nuclear generation is performed. At this time, it is desirable to appropriately supply a sodium hydroxide aqueous solution and ammonia water to maintain a pH value and an ammonium ion concentration of an aqueous solution for nuclear generation within the above ranges.

After completion of nuclear generation, an acid such as sulfuric acid is added to adjust the pH value so as to be 10 or more and 12 or less based on the liquid temperature of 25° C. and smaller than the pH value in the nuclear generation process, thereby forming an aqueous solution for particle growth. After verifying that the pH value has reached a predetermined value, the raw material aqueous solution is supplied to grow the nuclei (particles) generated in the nuclear generation process. Note that, when an aqueous solution containing a compound of the additive element M is separately prepared, the aqueous solution containing the compound of the additive element M can be added only in the particle growth process or only in a specific stage of the particle growth process.

As the first stage of particle growth, crystallization in a non-oxidizing atmosphere having an oxygen concentration of 2% by volume or less is continued for a certain period of time from start of the particle growth process while stirring is performed using a stirrer.

As the second stage, switching operation 1 is performed in which extremely fine bubbles of air or gas of an oxidizing atmosphere containing oxygen are circulated in the reaction tank using a micro-nano bubble generator while supply of the raw material aqueous solution is continued, and the reaction atmosphere is adjusted to an oxidizing atmosphere having an oxygen concentration of 21% by volume or more. After the switching operation 1 is started, crystallization is performed while the oxidizing atmosphere is maintained and stirring is performed using a stirrer for a certain period of time.

As the third stage, switching operation 2 is performed in which extremely fine bubbles of gas of a non-oxidizing atmosphere are circulated in the reaction tank using a micro-nano bubble generator while supply of the raw material aqueous solution is continued, and the reaction atmosphere is adjusted to a non-oxidizing atmosphere having an oxygen concentration of 2% by volume or less. After the switching operation 2 is started, crystallization is performed while the non-oxidizing atmosphere is maintained and stirring is performed using a stirrer for a certain period of time.

As the fourth stage, switching operation 3 is performed in which extremely fine bubbles of gas of an oxidizing atmosphere are circulated in the reaction tank using a micro-nano bubble generator while supply of the raw material aqueous solution is continued, and the reaction atmosphere is adjusted to an oxidizing atmosphere having an oxygen concentration of 21% by volume or more. After the switching operation 3 is started, crystallization is performed while the oxidizing atmosphere is maintained and stirring is performed using a stirrer for a certain period of time.

As the fifth stage, switching operation 4 is performed in which extremely fine bubbles of gas of a non-oxidizing atmosphere are circulated in the reaction tank using a micro-nano bubble generator while supply of the raw material aqueous solution is continued, and the reaction atmosphere is adjusted to a non-oxidizing atmosphere having an oxygen concentration of 2% by volume or less. After the switching operation 4 is started, crystallization is performed while the non-oxidizing atmosphere is maintained and stirring is performed using a stirrer for a certain period of time.

In the present invention, the micro-nano bubble generator is used as an apparatus for switching and maintaining the reaction atmosphere of the aqueous solution for particle growth. Since the diameter of a bubble (micro-nano bubble) generated by the micro-nano bubble generator is 0.01 mm or less and buoyancy thereof is small, the bubbles stay in water for a long time. Therefore, the reaction atmosphere is quickly switched by the non-oxidizing atmosphere gas and the oxidizing atmosphere gas, and the oxygen concentration thereof can be decreased or increased. Note that the micro-nano bubble generator is preferably used similarly also in the nuclear generation process from a viewpoint of quickly maintaining the reaction atmosphere to a non-oxidizing atmosphere having an oxygen concentration of 2% by volume or less and forming dense nuclei.

Time of each stage in the particle growth process satisfies second stage≤fourth stage<first stage≤third stage≤fifth stage. Crystallization time of the entire particle growth process is desirably eight hours or shorter.

The particle growth process can include the sixth stage in an oxidizing atmosphere and the seventh stage in a non-oxidizing atmosphere by similarly performing switching operations 5 and 6, respectively. Furthermore, the particle growth process can include the eighth stage in an oxidizing atmosphere and the ninth stage in a non-oxidizing atmosphere by performing switching operations 7 and 8, respectively. Furthermore, in addition, the particle growth process can include the tenth stage in an oxidizing atmosphere and the eleventh stage in a non-oxidizing atmosphere by performing switching operations 9 and 10, respectively.

Also in these cases, time of each stage in the particle growth process satisfies second stage≤fourth stage≤sixth stage o eighth stage o tenth stage<first stage≤third stage o fifth stage o seventh stage≤ninth stage≤eleventh stage. In each of the stages, the micro-nano bubble generator is used as an apparatus for switching and maintaining the reaction atmosphere of the aqueous solution for particle growth.

After completion of the crystallization, the obtained product is washed with water, filtered, and dried to obtain predetermined nickel-cobalt.-manganese-containing composite hydroxide particles.

In the particle growth process, it is desirable to appropriately supply a sodium hydroxide aqueous solution and ammonia water through the process to maintain a pH value and an ammonium ion concentration of the aqueous solution for particle growth within the above ranges.

The composite hydroxide particles obtained by such a crystallization process have a particle structure in which a low-density layer and a high-density layer are laminated on each other around a high-density center section. By using the composite hydroxide particles having such a particle structure as a precursor, composite oxide particles having a particle structure having an aggregated section, one or more communication holes communicating with an outer periphery section of the aggregated section, and two or more space sections present inside the aggregated section and communicating with the one or more communication holes can be easily obtained.

(2) Mixing Process

A mixing process is a process of mixing a lithium compound with the composite hydroxide particles described above or heat-treated particles obtained by heat-treating the composite hydroxide particles to obtain a lithium mixture.

In the mixing process, the composite hydroxide particles are mixed with the lithium compound such that a ratio (Li/Me) of the number of atoms of Li (Li) to the sum of the number of atoms (Me) of metal atoms other than Li in the lithium mixture, specifically, Ni, Mn, Co, and the additive element M is 0.95 or more and 1.5 or less, preferably 1.0 or more and 1.5 or less, more preferably 1.0 or more and 1.35 or less, and still more preferably 1.0 or more and 1.2 or less. That is, since Li/Me does not change after the firing process as compared with Li/Me before the firing process, it is necessary to mix the composite hydroxide with the lithium compound such that Li/Me in the mixing process is Li/Me of a target positive electrode active material.

The lithium compound used in the mixing process is not particularly limited, but lithium hydroxide, lithium nitrate, lithium carbonate, or a mixture of these is preferably used from a viewpoint, of easy availability. Particularly, lithium hydroxide or lithium carbonate is preferably used in consideration of ease of handling and stability of quality.

A general mixer can be used for mixing. For example, a shaker mixer, a Lodige mixer, a Julia mixer, or a V blender can be used.

(3) Calcination Process

When lithium hydroxide or lithium carbonate is used as the lithium compound, it is also possible to perform a calcination process of calcining the lithium mixture at a temperature lower than a firing temperature described below, and at a temperature of 350° C. or higher and S00° C. or lower, and preferably 450° C. or lower and 750° C. or lower-after the nixing process and before the firing process. As a result, it is possible to sufficiently diffuse Id. into the composite hydroxide particles, and more uniform composite oxide particles can be obtained.

Note that holding time at the above temperature is preferably one hour or longer and ten hours or shorter, and more preferably three hours or longer and six hours or shorter. Furthermore, the atmosphere in the calcination process is preferably an oxidizing atmosphere, and more preferably an atmosphere having an oxygen concentration of 13% by volume or more and 100% by volume or less as in the firing process described later.

(4) Firing Process

A firing process is a process of firing the lithium mixture obtained in the mixing process under a predetermined condition, and diffusing Li in the composite hydroxide to cause a reaction, thereby obtaining composite oxide particles.

A furnace used in the firing process is net particularly limited as long as the furnace can heat the lithium mixture in the air or an oxygen flow. However, an electric furnace that does not generate gas is preferable from a viewpoint of keeping the atmosphere in the furnace uniform, and either a batch type electric furnace or a continuous type electric furnace can be preferably used. This is also the same for the furnace used in the heat treatment process and the calcination process.

a) Firing Temperature

A firing temperature of the lithium mixture is set to 720° C. or higher and 390° C. or lower, When the firing temperature is lower than 720° C., the composite hydroxide particles and Li do not sufficiently react with each other, and excessive Li or unreacted composite hydroxide may remain, or the crystallinity of a positive electrode active material to be obtained may be insufficient. On the other hand, when the firing temperature exceeds 580° C., there is a possibility that the communication holes and space sections in the composite oxide particles are crushed to reduce the BET specific surface area of a positive electrode active material (secondary particles) to be finally obtained and to reduce the pore peak diameter thereof and the log differential pore volume thereof at the pore peak diameter. Furthermore, sintering between particles of the positive electrode active material severely occurs, abnormal grain growth is caused, and the ratio of coarse particles having an irregular shape increases.

By controlling the firing temperature, it is possible to control the BET specific surface area of the positive electrode active material (secondary particles), the pore peak diameter thereof and the log differential pore volume thereof at the pore peak diameter, and the 50% cumulative diameter d50 thereof determined from the particle size distribution measured value. The firing temperature of the lithium mixture is set to preferably 730° C. or higher and 970° C. or lower and more preferably 750° C. or higher and 970° C. or lower from a viewpoint of controlling the BET specific surface area of the positive electrode active material (secondary particles), the pore peak diameter thereof and the log differential pore volume thereof at the pore peak diameter, and the 50% cumulative diameter d50 thereof determined from the particle size distribution measured value.

A temperature rising rate in the firing process is set to preferably 1° C./min or more and 10° C./min or less and more preferably 3° C./min or more 8° C./min or less. Furthermore, during the firing process, at a temperature near the melting point of the lithium compound, it is more preferable to lower the temperature rising rate to set the temperature rising rate to 0.3° C./min or more and 6° C./min or less. As a result, a reaction between the composite hydroxide particles and the lithium compound can be caused more uniformly.

b) Firing Time

Of the firing time, time during which the temperature is maintained at the above-described firing temperature is set to preferably at least two hours and more preferably three hours or longer and 20 hours or shorter, when the time during which the temperature is maintained at the firing temperature is shorter than two hours, Li is not sufficiently diffused into the composite oxide particles, and excessive Li or unreacted composite oxide particles may remain, or the crystallinity of a positive electrode active material to be obtained may be insufficient.

c) Firing Atmosphere

An atmosphere when firing is preferably an oxidizing atmosphere, more preferably an atmosphere having an oxygen concentration of 18% by volume or more and 100% by volume or less, and still more preferably an atmosphere having an oxygen concentration of 50% by volume or more and 100% by volume or less. The atmosphere when firing is particularly preferably a mixed atmosphere of oxygen having the above oxygen concentration and an inert gas. That is, firing is preferably performed in the air or an oxygen flow. When the oxygen concentration is less than 18% by volume, the crystallinity of the positive electrode active material may be insufficient.

(5) Crushing Process

The secondary particles obtained by the firing process and to constitute a positive electrode active material nay be aggregated or slightly sintered. In such a case, the aggregate or sintered body is preferably crushed. This makes it possible to adjust the average particle size and the particle size distribution of a positive electrode active material to be obtained within a preferable range. Note that crushing means an operation of applying mechanical energy to an aggregate formed of a plurality of secondary particles generated by, for example, sintering necking between the particles when firing to separate the secondary particles from each other while hardly destroying the secondary particles themselves, thus loosening the aggregate.

A known means can be used for crushing, and for example, a pin mill or a hammer mill can be used. Note that at this time, a crushing force is preferably controlled within an appropriate range so as not to destroy the secondary particles themselves.

As described above, by adjusting the firing conditions, the BET specific surface area of the positive electrode active material (secondary particles), the pore peak diameter thereof and the log differential pore volume thereof at the pore peak diameter, and the 50% cumulative diameter d50 thereof determined from the particle size distribution measured value can be controlled, and finally, the positive electrode active material of the present invention having predetermined particle properties can be easily obtained.

3. Lithium Ion Secondary Battery

The lithium ion secondary battery of the present invention can adopt the same configuration as that of a general non-aqueous electrolyte secondary battery that includes constituent members such as a positive electrode, a negative electrode, a separator, and a non-aqueous electrolyte. Alternatively, the lithium ion secondary battery of the present invention can adopt the same configuration as that of a general solid electrolyte secondary battery that includes constituent members such as a positive electrode, a negative electrode, and a solid electrolyte. That is, the present invention can be widely applied to a secondary battery including a non-aqueous electrolyte solution secondary battery and an all-solid-state lithium ion secondary battery as long as the secondary battery is charged and discharged by de-inserting and inserting lithium ions. Note that embodiments described below are merely examples, and the present invention can be applied to lithium ion secondary batteries that are modified or improved in various ways based on the embodiments described in the present specification.

(1) Constituent Members

a) Positive Electrode

Using the positive electrode active material of the present invention, for example, a positive electrode of a lithium ion secondary battery is prepared as follows.

First, a conductive material and a binding agent are mixed with the positive electrode active material of the present invention. Further, activated carbon and a solvent, for example, for adjusting viscosity are added as necessary. These are kneaded to prepare a positive electrode mixture paste. At this time, a mixing ratio among the components in the positive electrode mixture paste is also an important factor for determining performance of the lithium ion secondary battery. For example, when the solid content of the positive electrode mixture excluding the solvent is 100 parts by mass, the content of the positive electrode active material can be 60 parts by mass or more and 95 parts by mass or less, the content of the conductive material can be 1 part by mass or more and 20 parts by mass or less, and the content of the binding agent can be 1 part by mass or more and 20 parts by mass or less as in a positive electrode of a general lithium ion secondary battery.

The obtained positive electrode mixture paste is applied to a surface of a collector, for example, made of aluminum foil and dried to scatter the solvent. Pressurization may be performed by a roll press or the like in order to increase the electrode density as necessary. In this way, a sheet-shaped positive electrode can be prepared. The sheet-shaped positive electrode is cut into an appropriate size according to a target battery, for example, and used for preparing a battery. Note that, the method for preparing a positive electrode is not limited to the exemplified one, and other methods may be used.

Examples of the conductive material include graphite (natural graphite, artificial graphite, expanded graphite, and the like) and a carbon black-based material such as acetylene black or Ketjen black.

The binding agent serves to hold the active material particles together, and examples thereof include polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), a fluorocarbon rubber, an ethylene propylene diene rubber, styrene butadiene, a cellulose-based resin, and polyacrylic acid.

In addition, a solvent that disperses the positive electrode active material, the conductive material, and the activated carbon and dissolves the binding agent can be added to the positive electrode mixture as necessary. Specifically, as the solvent, an organic solvent such as N-methyl-2-pyrrolidone can be used. Activated carbon can be added to the positive electrode mixture in order to increase electric double layer capacity.

b) Negative Electrode

Metallic lithium, a lithium alloy, or the like can be used for the negative electrode. Furthermore, a product formed by mixing a binding agent with a negative electrode active material capable of inserting and de-inserting lithium ions, adding an appropriate solvent thereto to form a paste-like negative electrode mixture, applying the negative electrode mixture to a surface of a collector made of metal foil such as copper, drying the negative electrode mixture, and compressing the resulting product to increase the electrode density as necessary can be used.

Examples of the negative electrode active material include a lithium-containing substance such as metallic lithium or a lithium alloy, natural graphite, artificial graphite, or a fired organic compound such as a phenolic resin, and a powdery carbon substance such as coke, which are capable of inserting and de-inserting lithium ions. In this case, as the negative electrode binding agent, similarly to the positive electrode, a fluorine-containing resin such as PVDF can be used, and as the solvent that disperses the negative electrode active material and the binding agent, an organic solvent such as N-methyl-2-pyrrolidone can be used.

c) Separator

The separator is sandwiched between the positive electrode and the negative electrode in the lithium ion secondary battery, and has a function of separating the positive electrode from the negative electrode and holding the electrolyte. As such a separator, for example, a polyethylene or polypropylene thin film having a large number of fine pores can be used. However, the separator is not particularly limited as long as having the above-described function. Furthermore, a solid electrolyte can also be used.

d) Electrolyte

As the non-aqueous electrolyte used in the non-aqueous electrolyte secondary battery, a non-aqueous electrolyte solution obtained by dissolving a lithium salt as a supporting salt in an organic solvent, or the like is used.

As the organic solvent used in the non-aqueous electrolyte solution, one selected from the group consisting of a cyclic carbonate such as ethylene carbonate, propylene carbonate, butylene carbonate, or trifluoropropylene carbonate, a chain carbonate such as diethyl carbonate, dimethyl carbonate, ethylmethyl carbonate, or dipropyl carbonate, an ether compound such as tetrahydrofuran, 2-methyltetrahydrofuran, or dimethoxy ethane, a sulfur compound such as ethylmethylsulfone or butanesulton, and a phosphorus compound such as triethyl phosphate or trioctyl phosphate can be used singly, or two or more selected therefrom can be used in mixture.

Examples of the supporting salt include LiPF₆, LiBF₄, LiClO₄, LiAsF₆, LiN(CF₃SO₂)₂, and a composite salt thereof.

Note that the non-aqueous electrolyte solution may contain a radical scavenger, a surfactant, a flame retardant, and the like.

A solid electrolyte used in a solid electrolyte secondary battery such as an all-solid-state lithium ion secondary battery has a property of withstanding a high voltage. As the solid electrolyte, there are an inorganic solid electrolyte and an organic solid electrolyte.

Examples of an oxide-based electrolyte include an oxide containing oxygen (O) and having lithium ion conductivity and electronic insulation properties, such as Li_(1.3)Al_(0.3)Ti_(1.7)(PO₄)₃, Li₃PO₄, Li₃PO₄N_(x), LiBO₂N_(x), LiNbO₃, LiTaO₃, Li₂SiO₃, Li₄SiO₄—Li₃PO₄, Li₄SiO₄—Li₃VO₄, Li₂O—B₂O₃—P₂O₅, Li₂O—SiO₂, Li₂O—B₂O₃—ZnO, Li_(1+x)Al_(x)Ti_(2-x)(PO₄)₃ (0≤X≤1), Li_(1+x)Al_(x)Ge_(2−x) (PO₄)₃ (0≤X≤1), LiTi₂(PO₄)₃, Li_(3x)La_(2/3−x)TiO₃ (0≤X≤⅔), Li₅La₃Ta2O₁₂, Li₇La₃Zr₂O₁₂, Li₆BaLa₂Ta₂O₁₂, or Li_(3.6)Si_(0.6)P_(0.4)O₄.

Examples of a sulfide solid electrolyte include a sulfide containing sulfur (S) and having lithium ion conductivity and electronic insulation properties, such as Li₂S—SiS₂, Li₂S—P₂S₅, LiI—Li₂S—SiS₂, LiI—Li₂S—P₂S₅, LiI—Li₂S—B₂S₃, Li₃PO₄—Li₂S—Si₂S, Li₃PO₄—Li₂S—SiS₂, LiPO₄—Li₂S—SiS, LiI—Li₂S—P₂O₅, or LiI—Li₃PO₄—P₂S₅.

Examples of the inorganic solid electrolyte other than the oxide-based electrolyte and the sulfide solid electrolyte include Li₃N, LiI, and Li₃N—LiI—LiOH.

As the organic solid electrolyte, a high-molecular-weight compound exhibiting ionic conductivity can be used. For example, polyethylene oxide, polypropylene oxide, copolymers thereof, or the like can be used. Furthermore, the organic solid electrolyte can contain a supporting salt (lithium salt).

Note that, when the solid electrolyte is used, in order to secure contact between the electrolyte and the positive electrode active material, a solid electrolyte can be mixed also in the positive electrode material.

(2) Configuration of Lithium Ion Secondary Battery

The configuration of the lithium ion secondary battery is not particularly limited, A configuration including a positive electrode, a negative electrode, a separator, a non-aqueous electrolyte, and the like in a non-aqueous electrolyte secondary battery or a configuration including a positive electrode, a negative electrode, a solid electrolyte, and the like in a solid electrolyte secondary battery nay be adopted. Furthermore, the shape of the secondary battery is not particularly limited, and various shapes such as a cylindrical shape or a layered shape can be adopted.

In the case of a non-aqueous electrolyte secondary battery, for example, the positive electrode and the negative electrode are laminated via the separator to form an electrode body, the obtained electrode body is impregnated with a non-aqueous electrolyte, a positive electrode collector is connected to a positive electrode terminal leading to the outside using a current collecting lead or the like, a negative electrode collector is connected to a negative electrode terminal leading to the outside using a current collecting lead or the like, and the resulting product is sealed in a battery case to complete a lithium ion secondary battery.

(3) Characteristics of Lithium Ion Secondary Battery

As described above, the lithium ion secondary battery of the present invention uses the positive electrode active material of the present invention as a positive electrode material, and is therefore excellent in output characteristics and durability characteristics

(4) Application of Lithium Ion Secondary Battery

As described above, the lithium ion secondary battery of the present invention is excellent in output characteristics and durability characteristics, and can be preferably used for a power supply of an electric tool or an environmental automobile which is required to have these characteristics at a high level.

EXAMPLES

Hereinafter, the present invention will be described in detail with reference to Examples and comparative Examples. Through a nuclear generation process and a particle growth process, a pH value of a reaction aqueous solution was measured by a pH controller, and by adjusting the supply amount of a sodium hydroxide aqueous solution based on the measured value, a fluctuation range of the pH value of the reaction aqueous solution in each of the processes was controlled to be within a range of ±0.2.

Example 1

a) Manufacture of Composite Hydroxide

[Nuclear Generation Process]

First, 17 L of water was put in a reaction tank, and the temperature in the tank was set to 40° C. while water was stirred. At this time, using a micro-nano bubble generator (micro-nano bubble high-efficiency gas-liquid reactor manufactured by NORITAKE Co., Ltd.) made of a ceramic porous body, extremely fine bubbles of nitrogen gas were circulated in the reaction tank for one hour to set the reaction atmosphere to a non-oxidizing atmosphere having an oxygen concentration of 2% by volume or less. Subsequently, a 25% by mass sodium hydroxide aqueous solution and 25% by mass ammonia water were supplied into the reaction tank in appropriate amounts, and adjustment was performed such that a pH value was 12.6 on the basis of the liquid temperature of 25° C. and an ammonium ion concentration was 10 g/L, thereby forming a pre-reaction aqueous solution.

At the same time, nickel sulfate, manganese sulfate, and cobalt sulfate were dissolved in water such that a solar ratio among the metal elements satisfied Ni:Co:Mn=5:2:3 to prepare a 2 mol/L raw material aqueous solution.

W was used as the additive element M. Sodium tungstate dihydrate was dissolved in water such that a molar ratio among the metal elements including the additive element K in composite hydroxide particles to be obtained was Ni:Mn:Co:W=5.0:2.0:3.0:0.1, thereby preparing a sodium tungstate aqueous solution.

Next, the raw material aqueous solution was supplied to the pre-reaction aqueous solution at 115 ml/min to form an aqueous solution for nuclear generation process, and nuclear generation was performed for one minute. At this time, a 25% by mass sodium hydroxide aqueous solution and 25% by mass ammonia water were supplied at an appropriate time to maintain the pH value and ammonium ion concentration of the aqueous solution for nuclear generation within the above ranges.

[Particle Growth Process]

After completion of nuclear generation, supply of all the aqueous solutions was stopped temporarily, and sulfuric acid was added to adjust the pH value to 11.0 based on the liquid temperature of 25° C., thereby forming an aqueous solution for particle growth. It was confirmed that the pH value had reached a predetermined value. Thereafter, the raw material aqueous solution was supplied at a similar constant rate of 100 ml/min to that in the nuclear generation process to grow the nuclei (particles) generated in the nuclear generation process. Note that the sodium tungstate aqueous solution was supplied at a constant rate of 10 ml/min simultaneously with the raw material aqueous solution in a third stage and a fourth stage.

As the first stage, crystallization in a non-oxidizing atmosphere having an oxygen concentration of 2% by volume or less was continued for 35 minutes from start of the particle growth process while stirring was performed using a stirrer and extremely fine bubbles of nitrogen gas were circulated using the micro-nano bubble generator.

As the second stage, extremely fine bubbles of air were circulated in the reaction tank using the micro-nano bubble generator while supply of the raw material aqueous solution was continued, and the reaction atmosphere was adjusted to an oxidizing atmosphere having an oxygen concentration of 21% by volume (switching operation 1). After the switching operation 1 was started, crystallization was performed for 20 minutes while the oxidizing atmosphere was maintained and stirring was performed using a stirrer.

As the third stage, extremely fine bubbles of nitrogen were circulated in the reaction tank using the micro-nano bubble generator while supply of the raw material aqueous solution was continued and a sodium tungstate aqueous solution was supplied, and the reaction atmosphere was adjusted to a non-oxidizing atmosphere having an oxygen concentration of 2% by volume or less (switching operation 2). After the switching operation 2 was started, crystallization was performed for 65 minutes while the non-oxidizing atmosphere was maintained and stirring was performed using a stirrer.

As the fourth stage, extremely fine bubbles of air were circulated in the reaction tank using the micro-nano bubble generator while supply of the raw material aqueous solution and the sodium tungstate aqueous solution was continued, and adjustment to an oxidizing atmosphere having an oxygen concentration of 21% by volume was performed (switching operation 3). After the switching operation 3 was started, crystallization was performed for 40 minutes while the oxidizing atmosphere was maintained and stirring was performed using a stirrer.

As the fifth stage, extremely fine bubbles of nitrogen were circulated in the reaction tank using the micro-nano bubble generator while supply of the sodium tungstate aqueous solution was stopped and supply of the raw material aqueous solution was continued, and the reaction atmosphere was adjusted to a non-oxidizing atmosphere having an oxygen concentration of 2% by volume or less (switching operation 4). After the switching operation 4 was started, crystallization was performed: 110 minutes while the non-oxidizing atmosphere was maintained and stirring was performed using a stirrer.

Thereafter, supply of all the aqueous solutions including the raw material aqueous solution was stopped to complete the particle growth process. The obtained product was washed with water, filtered, and dried to obtain composite hydroxide particles.

Note that, in the particle growth process, a 25% by mass sodium hydroxide aqueous solution and 25% by mass ammonia water were appropriately supplied through the process to maintain the pH value and ammonium ion concentration of the aqueous solution for particle growth within the above ranges.

b) Preparation of Positive Electrode Active Material

The obtained composite hydroxide was sufficiently mixed with lithium hydroxide using a shaker mixer such that Li/Me was 1.10 to obtain a lithium mixture (mixing process).

The temperature of this lithium mixture was raised to 965° C. in an oxygen (oxygen concentration: 100% by volume) atmosphere at a temperature rising rate of 1.3° C./min. The lithium mixture was held at this temperature for three hours to be fired, and cooled to room temperature (firing process).

In order to eliminate aggregation or slight sintering of the obtained lithium transition metal-containing composite oxide particles, this positive electrode active material was crushed (crushing process).

c) Evaluation of Positive Electrode Active Material

[Composition]

The composition of the positive electrode active material was analyzed by analysis using an ICP emission spectrometer (ICPE-9000 manufactured by Shimadzu Corporation).

[Particle Size Distribution]

Using a laser light diffraction scattering particle size analyzer (Microtrac MT 3300 EXII manufactured by Microtrac Bell Co., Ltd.), the 50% cumulative diameter d50, the 10% cumulative diameter d10, and the 90% cumulative diameter d90 of the positive electrode active material (secondary particles) determined from the particle size distribution measured value were measured.

[BET Specific Surface Area]

Using an independent four-station type specific surface area/pore distribution measuring apparatus (QUADRASORB SI manufactured by Quantachrome Instruments), the BET specific surface area of the positive electrode active material (secondary particles) was determined.

[Pore Peak Diameter and Log Differential Pore Volume at the Pore Peak Diameter]

The pore peak diameter of the positive electrode active material (secondary particles) and the log differential pore volume thereof at the pore peak diameter were determined by a mercury intrusion method using an automatic mercury porosimeter pore distribution measuring apparatus (AutoPore IV 9520 manufactured by Micromeritics, Inc.).

[Particle Structure]

A part of the positive electrode active material was embedded in a resin, cross section polisher (IB-19530CP manufactured by JEOL Ltd.) processing was performed such that a cross section thereof could be observed, and then the cross section was observed by an SEM (FE-SEM: JSM-6360LA manufactured by JEOL Ltd.). As shown in FIG. 1 , it was confirmed that the positive electrode active material of the present invention included a secondary particle formed of an aggregation of a plurality of primary particles, had about six communication holes in an outer periphery section of the secondary particle, and had about eight space sections in the secondary particle, and that the communication holes in the outer periphery section and internal space sections were connected to each other.

[Coefficient of Variation]

A cross section of the positive electrode active material (secondary particles) was sectioned using an ion milling apparatus (Cryoion slicer IB-09060CIS manufactured by JEOL Ltd.). Using a TEM (JEM-ARM200F manufactured by JEOL Ltd.), primary particles having a particle size of about 0.5 μm (two particles linked with each other with a grain boundary interposed therebetween) in the cross section of the secondary particles were targeted, and a total of ten locations arbitrarily selected from the entire primary particles including insides of the primary particles and the grain boundary of the primary particles were irradiated with an electron beam. Energy of a generated characteristic X-ray of W was analyzed using EDX (NSS manufactured by Thermo Fisher Scientific), and an average concentration (μ) of W, a standard deviation (σ) of the concentration of W, and a coefficient of variation (CV) of the concentration of W in the entire primary particles were analyzed. The measurement results of the concentration of W for the obtained primary particles by TEM-EDX analysis are presented in Table 1.

As a result, the average concentration (μ) of W was 1.0, the standard deviation (σ) of the concentration of W was 1.1, and the coefficient of variation (CV) of the concentration of W was 1.1.

TABLE 1 Additive element (W) 1 Grain boundary 1.8 2 Grain boundary 2.4 3 Grain boundary 1.5 4 Grain boundary 1.3 5 Inside of particle 0.2 6 Inside of particle 0.1 7 Inside of particle 0.2 8 Inside of particle 0.2 9 Inside of particle 2.8 10 Inside of particle 0.2 Average M 1.1 Standard deviation σ 1.0 Coefficient of variation CV 1.0

d) Preparation of Secondary Battery

A 2032 type coin-type battery 10 as illustrated in FIG. 3 was prepared. Specifically, 52.5 mg of the positive electrode active material obtained as described above, 15 mg of acetylene black, and 7.5 mg of FIFE were mixed and press-molded to a diameter of 11 mm and a thickness of 100 μm at a pressure of 100 MPa, thereby preparing a positive electrode 1.

Next, using this positive electrode 1, a 2032 type coin-type battery was prepared in a glove box having an Ar atmosphere with a dew point controlled at −60° C. For a negative electrode 2 of the 2032 type coin-type battery, a lithium metal having a diameter of 14 mm and a thickness of 1 mm was used. For a non-aqueous electrolyte solution, an equivalent mixed solution of ethylene carbonate (EC) and diethyl carbonate (DEC) using 1 M LiClO₄ as a supporting electrolyte (manufactured by Ube Industries, Ltd.) was used. For a separator 3, a polyethylene porous film having a film thickness of 25 μm was used. In this way, the 2032 type coin-type battery 10 having a gasket 4 and a wave washer 5 and including a positive electrode can 6 and a negative electrode can 7 was assembled.

e) Battery Evaluation

[Positive Electrode Resistance]

In measurement of positive electrode resistance, a 2032 type coin-type battery was charged at 3.8 V using an impedance measuring method, and the positive electrode resistance was measured using a frequency response analyzer and a potentiogalvanostat (1255B manufactured by Solartron Analytical Inc.) by an AC impedance method to obtain an impedance spectrum illustrated in FIG. 4 . In the obtained impedance spectrum, two semicircles were observed in a high frequency area and an intermediate frequency area, and a straight line was observed in a low frequency area. Therefore, an equivalent circuit illustrated in FIG. 5 was assembled, and positive electrode interface resistance was analyzed. Here, Rs represents bulk resistance, R₁ represents positive electrode coating film resistance, R_(ct) represents electrolyte solution/positive electrode interface resistance, W represents a Warburg component, and CPE1 and CPE2 represent constant phase elements. Note that the positive electrode interface resistance indicates a resistance decrease ratio with respect to positive electrode interface resistance of a positive electrode active material of Comparative Example 1 described below.

The overall composition and characteristics of the obtained positive electrode active material and the characteristics of the obtained lithium ion secondary battery are presented in Table 2. Note that these items of Examples 2 to 5 and Comparative Examples 1 and 2 are also presented in Table 1 similarly.

Example 2

A positive electrode active material was obtained and evaluated in a similar manner to Example 1 except that the lithium mixture was heated to 915° C. and held at this temperature for three hours for firing.

Example 3

A positive electrode active material was obtained and evaluated in a similar manner to Example 2 except that a sodium tungstate aqueous solution was prepared such that a molar ratio among the metal elements was Ni:Mn:Co:W=5.0:2.0:3.0:0.07.

Example 4

A positive electrode active material was obtained and evaluated in a similar manner to Example 1 except that the lithium mixture was fired at 985° C.

Example 5

A positive electrode active material was obtained and evaluated in a similar manner to Example 1 except that the lithium mixture was fired at 885° C.

Comparative Example 1

A positive electrode active material was obtained and evaluated in a similar manner to Example 1 except that in the crystallization process, crystallization was performed by adjusting the atmosphere to an oxidizing atmosphere having an oxygen concentration of 21% by volume from the nuclear generation process up to the switching operation 1 in the particle growth process entirely, and by adjusting the atmosphere to a non-oxidizing atmosphere having an oxygen concentration of 2% by volume or less in the subsequent process, and thus a composite hydroxide was obtained. FIG. 2 shows a particle structure of the obtained positive electrode active material. It was confirmed that the positive electrode active material of Comparative Example 1 has a hollow structure in which secondary particles are each formed of an aggregation of a plurality of primary particles, the secondary particles each having one communication hole in an outer periphery section of the secondary particle, and having one space section in the secondary particle, the communication hole in the outer periphery section and the internal void being connected to each other.

Comparative Example 2

A positive electrode active material was obtained and evaluated in a similar manner to Example 1 except that the lithium mixture was fired at 815° C.

TABLE 2 Positive log W concen- electrode BET Pore differ- tration Particle structure interface specific peak ential coefficient Number of Number resistance surface diam- pore of (d90 − communi- of (based on D50 area eter volume variation d10)/ d90/ cation space Comparative Composition (μm) (m²/g) (μm) (ml/g) (CV) d50 d10 holes sections Example 1) Example 1 Li_(1.1)Ni_(0.496)Mn_(0.296)Co_(0.198)W_(0.010)O₂ 5.0 2.8 0.10 0.39 1.2 0.45 1.5 6 8 0.85 Example 2 Li_(1.1)Ni_(0.496)Mn_(0.296)Co_(0.198)W_(0.010)O₂ 5.1 4.0 0.11 0.42 1.2 0.44 1.4 16 25 0.76 Example 3 Li_(1.1)Ni_(0.497)Mn_(0.297)Co_(0.198)W_(0.007)O₂ 5.1 3.5 0.10 0.41 1.2 0.45 1.5 11 19 0.65 Example 4 Li_(1.1)Ni_(0.496)Mn_(0.296)Co_(0.198)W_(0.010)O₂ 4.7 1.9 0.10 0.2 1.2 0.45 1.5 5 10 0.95 Example 5 Li_(1.1)Ni_(0.496)Mn_(0.296)Co_(0.198)W_(0.010)O₂ 5.2 5.4 0.10 0.5 1.2 0.45 1.5 20 31 0.86 Comparative Li_(1.1)Ni_(0.496)Mn_(0.296)Co_(0.198)W_(0.010)O₂ 5.1 1.2 0.08 0.006 1.2 0.44 1.4 1 1 1 Example 1 Comparative Li_(1.1)Ni_(0.496)Mn_(0.296)Co_(0.198)W_(0.010)O₂ 5.3 5.6 0.11 0.7 1.2 0.45 1.5 24 35 1.1 Example 2

In each of the positive electrode active materials of Examples 1 to 5 within the scope of the present invention, it was confirmed that positive electrode resistance was reduced and output characteristics were improved when each of the positive electrode active materials was used in a lithium ion secondary battery, as compared with those of Comparative Examples 1 and 2.

REFERENCE SIGNS LIST

1 Positive electrode (electrode for evaluation)

2 Negative electrode

3 Separator

4 Gasket

5 Wave washer

6 Positive electrode can

7 Negative electrode can

10 Coin-type battery 

1. A positive electrode active material for a lithium ion secondary battery, the positive electrode active material comprising composite oxide particles constituted by lithium transition metal-containing composite oxide particles having a composition represented by general formula (A): Li_(1+n)Ni_(x)Mn_(y)Co_(z)M_(t)O₂, where −0.05≤u≤0.5, x+y+z+t=1, 0.3≤x≤0.9, 0≤y≤0.5. 0≤z≤0.5, 0≤t≤0.1, and M is one or more additive elements selected from Mg, Al, Si, Ca, Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, and W, and a layered rock salt type crystal structure, the lithium transition metal-containing composite oxide particle being composed of secondary particles, the secondary particles each formed of an aggregation of primary particles, and the secondary particles having: a 50% cumulative diameter d50 of 3.0 μm or more and 7.0 μm or less, the 50% cumulative diameter d50 being determined from a particle size distribution measured value; a BET specific surface area of 1.8 m²/g or more and 5.5 m²/g or less; a pore peak diameter of 0.01 μm or more and 0.30 μm or less in a pore portion obtained by a mercury intrusion method; and a log differential pore volume [dV/d(log D)] of 0.2 ml/g or more and 0.6 ml/g or less within a range of the pore peak diameter of 0.01 μm or more and 0.30 μm or less, and for each of a plurality of primary particles having a primary particle size within a range of 0.1 μm or more and 1.0 μm or less among the primary particles, when a concentration of the additive element M is measured at a plurality of locations by cross-sectional STEM or TEM-EDX analysis, and a coefficient of variation of the concentration of the additive element M, which is a value obtained by dividing a standard deviation of the concentration of the additive element M by an average concentration of the additive element M, is calculated, the coefficient of variation being 1.5 or less.
 2. The positive electrode active material for a lithium ion secondary battery according to claim 1, wherein the 50% cumulative diameter d50 of the secondary particles is 4.0 μm or more and 6.0 μm or less.
 3. The positive electrode active material for a lithium ion secondary battery according to claim 1, wherein [(d90−d10)/d50], where d10 is a 10% cumulative diameter determined from a particle size distribution measured value, and d90 is a 90% cumulative diameter determined from the particle size distribution measured value, the [(d90−d10)/d50] being an index indicating spread of a particle size distribution of the secondary particles, is 1.0 or less.
 4. The positive electrode active material for a lithium ion secondary battery according to claim 1, wherein a value of d90/d10 of the secondary particles, where d10 is a 10% cumulative diameter determined from a particle size distribution measured value, and d90 is a 90% cumulative diameter determined from the particle size distribution measured value, is 1.0 or more and 2.0 or less.
 5. The positive electrode active material for a lithium ion secondary battery according to claim 1, wherein the secondary particle has an aggregated section, one or more communication holes communicating with an outer periphery section of the aggregated section, and two or more space sections present inside the aggregated section and communicating with the one or more communication holes.
 6. The positive electrode active material for a lithium ion secondary battery according to claim 1, wherein the additive element M is at least one selected from the group consisting of Mg, Al, Si, Ti, Zr, Nb, Mo, and W.
 7. The positive electrode active material for a lithium ion secondary battery according to claim 1, wherein the additive element M is W.
 8. A lithium ion secondary battery comprising: a positive electrode, a negative electrode; a separator; and a non-aqueous electrolyte, or a positive electrode, a negative electrode; and a solid electrolyte, wherein the positive electrode active material for a lithium ion secondary battery according to claim 1 is used as a positive electrode active material used in the positive electrode. 